Crank Case Cap & Timing Cap

[MKE.rob]

Tips for getting these off?




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[Arky-X]

I used the largest flat blade screwdriver I had with a rag around it so it wouldn't scar or leave markings on the caps.

[Shep1970]

A quarter and vice grips.

shep

[shortline10]

As a last resort if their real stuck I use a small punch and tap them
Loose .

[Dirtcrasher]

Use a large fender washer, it's super important that it sits in there and grabs that whole semi circle. Screwdrivers will mark them up 75% of the time unless they are in there very easy.

Make sure you put grease on the threads and the O-ring when you put it back together, they'll come out easier next time.

I think the 400EX and/or 450R caps can be used (I'd have to look in my notes) but that's how I got anodized caps.

Oh, and 250SX caps fit the 350X perfectly or vice versa so that opens up some swaps...

[Shawn Powell]

Use a large fender washer, it's super important that it sits in there and grabs that whole semi circle. Screwdrivers will mark them up 75% of the time unless they are in there very easy.

Make sure you put grease on the threads and the O-ring when you put it back together, they'll come out easier next time.

I think the 400EX and/or 450R caps can be used (I'd have to look in my notes) but that's how I got anodized caps.

Oh, and 250SX caps fit the 350X perfectly or vice versa so that opens up some swaps...

400ex caps fit. Almost anything in that style motor works. I have tusk anodized ones for a 400ex in my 350x. Also the same cap for the xl600r xr600r xr400 Xr250r Xr650l. Those are just ones I know fit cause I own them. I had to tap mine loose with a punch when I bought mine as they were already stripped and too tight. Good luck.


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[MKE.rob]

Use a large fender washer, it's super important that it sits in there and grabs that whole semi circle. Screwdrivers will mark them up 75% of the time unless they are in there very easy.

Make sure you put grease on the threads and the O-ring when you put it back together, they'll come out easier next time.

I think the 400EX and/or 450R caps can be used (I'd have to look in my notes) but that's how I got anodized caps.

Oh, and 250SX caps fit the 350X perfectly or vice versa so that opens up some swaps...

Any idea where to get the o-ring for both the caps? Also what type of grease are you using?


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[kb0nly]

I used to fight those caps all the time, then i made a tool for it. I have one of those old school impact drivers you hit with a , i took the largest flat blade bit for it and milled both sides down a bit and took some off the end to make a square flat blade, like a gunsmiths screwdriver its not tapered into a wedge like most flat screwdrivers. That and a quick blow of the rubber mallet on the impact driver pops them free every time first hit.

When putting them back together i just use a bit of multi purpose grease, axle and bearing grease, keeps them easily removable in the future. The O-rings are still available on Partzilla, or if you got a good parts store they might have something size wise thats similar.

O-RING (13.8X2.5)
91303-377-000

O-RING (27X2)
91305-KF0-003

[MKE.rob]

I used to fight those caps all the time, then i made a tool for it. I have one of those old school impact drivers you hit with a , i took the largest flat blade bit for it and milled both sides down a bit and took some off the end to make a square flat blade, like a gunsmiths screwdriver its not tapered into a wedge like most flat screwdrivers. That and a quick blow of the rubber mallet on the impact driver pops them free every time first hit.

When putting them back together i just use a bit of multi purpose grease, axle and bearing grease, keeps them easily removable in the future. The O-rings are still available on Partzilla, or if you got a good parts store they might have something size wise thats similar.

O-RING (13.8X2.5)
91303-377-000

O-RING (27X2)
91305-KF0-003

Thank you very much! Buddy had an impact driver that he let me borrow so I’ll take a stab at it tomorrow.


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[Dirtcrasher]

You'll end up paying 20$ for those 2 O rings with shipping.

Any type of grease will keep the rubber from binding up, that's what holds them in so tight.

I put a dab of grease on most bolts I use, even gaskets (aside from head gaskets) and all my stuff comes apart easily and I can reuse gaskets , they never stick to the case.

[MKE.rob]

You'll end up paying 20$ for those 2 O rings with shipping.

Any type of grease will keep the rubber from binding up, that's what holds them in so tight.

I put a dab of grease on most bolts I use, even gaskets (aside from head gaskets) and all my stuff comes apart easily and I can reuse gaskets , they never stick to the case.

Yeah I bought 3 sets of o-rings. One for each 250sx and an extra set. $27. Plan to lubricate everything up when I put it back so I don’t have this issue down the road. Thanks!


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[ATC King]

I think the 400EX and/or 450R caps can be used (I'd have to look in my notes) but that's how I got anodized caps.

Caps for the Honda XR dirt bikes may fit too. It seems like I've read that someone on here in the past.

Just throwing that up since you mentioned alternative caps.
https://www.xrsonly.com/30mm-side-case-plug


Some like those on EBay too and also with a allen cap, if that recessed style sits in too much.

[kb0nly]

I've seen a few replacement styles as well. On my 81 200 the timing cap was really stuck, i thrashed it getting it out. I was going to clean it up but i decided to make a new one on the lathe and mill, i started with a dodge/chrysler oil drain plug that i found that was the same size thread, shorted the threaded portion, cut down the flange of the head so it would fit in the recess on the lathe and put in a small recess at the flange to hold the o-ring to seal it up and now i have a timing plug that has a hex head that takes a wrench. So its not impossible to replace them with something better.